Manufacturing Continuous Improvement Using Lean Six Sigma: An Iron Ores Industry Case Application

In Iron Ores Industry, manufacturing process capability is an important factor for business continuity. There are some problems faced in manufacturing process that caused inability to fulfill the manufacturing quantity target. In order to improve the manufacturing process capability, this research is conducted using lean six sigma method. The first part is focused on waste analysis using process activity mapping. Then manufacturing process capability is evaluated. Further, failure mode and effect analysis is used as a basic consideration in developing the continuous improvement program. The research shows that the quality performance is in the level of 2,97 sigma. There are 33,67% non value added activity and 14,2% non necessary non value added activity that occurs during the manufacturing process. Based on the analysis, product defects, inappropriate processing and waiting are type of manufacturing waste that frequently occurs. A continuous improvement program is develop to overcome that problem. The program consist of redesigning chute dust collector, weighing standard operation procedures, BC 05 erection, vibro meter installation and nitrogen plant installation.